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Lubrication and Wear(Why, what, when, where, who

& The Need to do Better)

Ken J. Brown, MASc, P.Eng, FSTLE, CLSEco Fluid Center Ltd., Toronto

416 466-3144 www.fluidcenter.com

Why would you be hired?

To provide a function or service to help thecompany make money.

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What do you offer?

Maybe cheaper, smarter and/or faster.

What can you offer?

Maybe fresh ideas, new procedures and/or afamiliarity with new requirements and/or a

wiliness to adapt plus an ability to use a range ofresources to help provide effective solutions.

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Job Sectors

Manufacturing

Resources

Service

Sales

Financial

With all of these areas there is usually somethingthat might wear out, could be more efficient,

could last longer, or might work faster.

How will you contribute?

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The role of good design

Just as a good design takes into account functionas well as safety and sustainability, maintainabilityis extremely important for economic viability.

If you want it done right it has to easy to do it right.

Maintenance Options

Is what is done to keep equipment running. How youdo it can determine whether the facility keeps running.

Types: Fix or repair when;

Failure Maintenance: when it is broken.

Preventative Maintenance: based on time.

Predictive Maintenance: when some conditionindicates it is necessary.

Proactive Maintenance: Taking actions to preventfailures and/or to mitigate the consequences.

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http://www.maintenanceresources.com/referencelibrary/oilanalysis/oa-what.htm

Tribology

This is from the Greek word tribos. Tribology isthe science and engineering of interactingsurfaces in relative motion.

It includes the study and application of theprinciples of friction, lubrication and wear.

This includes lubricants, but also seals,bearings, wear, metal working, conditionmonitoring and numerous related fields. Plus,ceramics, biomaterials, plastics and frictionmaterials.

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Why?

With rotating equipment such as pumps, motors,fans, turbines and computer hard drives you havea rotating shaft or disc and stationary supports.

What supports them are bearings that usuallyrequires a lubricant.

The lubricant is what you provide, lubrication iswhat you do to keep the amounts correct andcondition monitoring is what you do to know whatis happening.

Note: For monitoring the purpose is not just for thelube but also the bearings and the health of theequipment.

Brown’s First Law Of Applied Tribology

(Power Generation)

If it's running,It's wearing

If it's not running,It's probably worn!

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Corollary 1: if not the above then it maybe on standby in case something elsewears out.

Corollary 2: if the equipment is noteconomical to run, this is probablybecause of a loss of efficiency as a resultof wear.

First and Foremost - Viscosity

The viscosity of a fluid is a measure of its

resistance to gradual deformation by stress. For

liquids, it corresponds to the concept of

"thickness".

For example, honey has a much higher viscosity

than water.

Ref: https://en.wikipedia.org/wiki/Viscosity

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Viscosity cont’d

Viscosity is a property arising from collisions between

neighboring particles in a fluid that are moving at

different velocities.

When the fluid is forced through a tube, the particles

which compose the fluid generally move more quickly

near the tube's center and more slowly near its walls:

therefore some stress, (such as a pressure difference

between the two ends of the tube), is needed to

overcome the friction between particle layers to keep

the fluid moving.

Capillary Viscometer

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Moving Surfaces - Stribeck Curve

Surfaces in contact means wear.

Ref: 2013 PC Lube Handbook

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Ref: 2013 PetroCanada Lubricants Handbook

Ref: 2013 PetroCanada Lubricants Handbook

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Centipoise

(cP)

Centistokes

(cSt)

Water 1.0 1.002

SAE 10 oil 70 80

Olive oil 100 110

SAE 30 oil 300 350

Glycerin 500 400

SAE 50 oil 800 910

Honey 2,000 1,430

Viscosities of Common Fluids

SAE Automotive Engine Oils

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SAE Gear Oils

Ref: Petro-Canada 2013 Product Handbook

SAE ViscosityGrade

MaximumTemperature for

Viscosity of150,000 cP, °C

KinematicViscosity at100°C, cStMinimum

70W -55 4.1

75W -40 4.1

80W -26 7.0

85W -12 11.0

SN introduced in October 2010.

Designed to provide improved high temperaturedeposit protection for pistons, more stringent sludgecontrol, and seal compatibility.

API Engine OilService Categories

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Use what is your manual OR most recent.

Caution. Oils are backwards compatible but not theother way. Some retailers reportedly sell olderversions.

For example API SA contains no additives. Not suitablefor use in most gasoline-powered automotive enginesbuilt after 1930. Use in modern engines may causeunsatisfactory performance or equipment harm.

API Engine Oil Service Categories

Know How to Read Labels

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Passenger Car Viscosity Grade Use

0W-20, 0W-30, 5W-20, 5W-30, 10W-30,10W-40

-18°C (0°F)

0W-20, 0W-30, 5W-20, 5W-30

Below -18°C (0°F)

0W-20, 0W-30, 5W-20, 5W-30, 10W-30,10W-40, 20W-50

0°C (32°F)

Typical SAE GradesIf the lowestexpected outdoortemperature is;

Note: This is a rough guide from the API.Follow OEM recommendations first.

Typical Motor Oil Additives

Viscosity Index Improvers (VI Improvers)

Dispersants

Detergents

Extreme-pressure/antiwear agents

Antioxidants/Inhibitors

Antifoam agents

Friction modifiers

Metal deactivators

Pour-point depressants

Rust-corrosion inhibitors

https://www.americanchemistry.com/paptg

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Greases

Oils tend to flow so in cases where you want thelubricants to stay in place but still have somemobility, they use thickeners.

This might be 10-20% of the final productdepending on the thickener used and how stiff youwant the grease. There are a number of thickenersystems including soaps like lithium 12hydroxystearate and non soaps such as clay,polyurea and calcium sulphonate.

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Grease vs. Oil

Lower limiting speeds

Cooling

Retains wear particles

Sampling

Harder to change

Stays in place

Simpler housings

Can contain solids

Keeps out contaminants

Can be replenished

Grease ConsGrease Pros

Issues

Most electric motors are designed with grease-

lubricated, antifriction, rolling element bearings.

Grease is the lifeblood of these bearings because it

provides an oil film that prevents the harsh metal-

to-metal contact between the rotating element and

races.

BUT!

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Issues cont’d

Bearing troubles account for 50 to 65 percent of

all electric motor failures, and poor lubrication

practices account for most of these bearing

troubles.

Proper maintenance procedures, planning and

the use of the correct lubricant can increase

productivity by reducing these bearing troubles

and motor failures.

Ref: http://www.machinerylubrication.com/Read/1125/electric-motor-lubrication

Ref: Ward, W., ‘Understanding Calcium Sulfonate Thickeners’,

Machinery Lubrication, Jul 2006

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NLGI GradeNLGI Grade PenetrationPenetration

000000 445445--475475

0000 400400--430430

00 355355--385385

11 310310--340340

22 265265--295295

33 220220--250250

44 175175--205205

55 130130--160160

66 8585--115115

Note: The grade has nothing to do with quality.

Grease Stiffness Grades

Grease Characteristics

The various greases have characteristics that makethem good for different applications. There is nosuch thing as a universal grease, but there can begeneral purpose greases.

Some desirable characteristics include thefollowing; oxidation resistance, wear protection,corrosion protection, water washout resistance,mechanical stability, resistance to oil separation,high temperature stability, low temperaturemobility, etc.

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Grease Thickener Characteristics

Ref: PetroCanada 2013 Lubricants Handbook

Grease Mixing

Just like mixing oils can be a bad idea because the

additives could be incompatible, mixing greases has

the added risk of thickener incompatibility. In these

cases the structure can fall apart and it is no longer

a grease or at least softens too much.

Charts are available but if in doubt or for an

important piece of equipment run a compatibility

test in different mixing ratios.

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Ref: Chemtura Canada Co.

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The "Right" Stuff

Achieving real benefits requires trueconsideration of the five R’s of lubrication.

right lubricant

right amount

right place

right time

right way

Missing even one can mean failure. Fortunatelyit is generally just as easy to do it right, IF theyknow how.

Ref: ‘Lubricant management for non-circulating sumps’, M.Johnson, TLT, August 2009 pp 16-23

So How Are We Doing?

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Rolling Element Bearings Lives - Now

New life theory (ISO 281:2007) takes into accountthe viscosity ratio of actual vs. required, type ofbearing, type of loading and cleanliness of the oil.

Lnaa = a1 aISO(C/P)3

Lnaa = adjusted rating life in millions of revolutions

a1 = life adjustment for reliability (i.e. 10% failure)

aISO = life adjustment factor based on new life theory

C = Basic load rating

P = Equivalent dynamic bearing load

Rolling Element Bearings Lives - Now

Life Modification Factor aISO

Among other things considers the influence of:

Fatigue limit of the bearing material by the

fatigue load limit C.

Grade of contaminations by the factor ec.

Lubrication conditions by the viscosity ratio K.

Note: ISO 281:2007 does not cover the influence of wear, corrosion and

electrical erosion on bearing life.

Ref: www.cwbearing.com

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Rolling Element Bearings

Unfortunately the leading causes of failuresare reported to be improper lubrication andimproper mounting.

‘These are preventable.’

Ref: Hafner, E.R., ‘Proper Lubrication-The Key To Better BearingLife, Part 1: Selecting The Correct Lubricant’, Mech. Eng., pp 32-37, October 1977

In real life it has been reported contaminants cause50% of bearing failures.

Rolling Element Bearings

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Rolling Element Bearings

Remaining causes are;

Marginal lubrication 30 %Other 17 %Fatigue life 3 %!!!

It was reported that they typically fail at 20%of their catalogue life. Again this is a realwaste.

Ref: NSK as reported in Machinery & Equipment MRO, p13 June 1999

Sources of Problems In Fluid Systems

Ref: Rexroth Oil Contamination Booklet RE 08016 2011

More than 3/4 of all problemscan be traced back to

contaminated oil. Monitoringoil cleanliness is therefore the

most important factor inpreventing system failures.

Monitoring hardware only detects around 20%of all unplanned downtimes.

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Ref: www.mapro.skf.com/products/

ProactiveProactive –– Do TheyDo TheyHave the Right Tools?Have the Right Tools?

BEARINGS

Ball Bearing Systems 15/13/11

Roller Bearing Systems 16/14/12

Journal Bearings (high speed) 17/15/13 >400 RPM

Journal Bearings (low speed) 18/16/14 <400 RPM

General Industrial Gearboxes 17/15/13

Ref: Eaton Vickers – The Systemic Approach to Contamination Control

Recommended ISO Cleanliness Codes>4 / >6 / >14 microns

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Fluid Additions –Condition Monitoring?

Ref: Des-Case

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Visual – Pressure Indicators –some are not so good

Fluid Additions –Condition Monitoring?

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Ref: www.mapro.skf.com/products/

Proper sized adapter ring, impactssleeves and a soft tipped hammer.

Proactive – Do TheyHave the Right Tools?

Ref: www.mapro.skf.com/products/

Mounting forces must not passthrough the rolling elements

Proactive – Do They Have

the Right Training?

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Ref: www.pruftechnik.com

Analysis – Where & What?

For monitoring use the same place every time.

Ref: :http://www.reliableplant.com/Read/27324

Approximate BearingFrequencies And Harmonics

Ball Pass Frequency Outer Race (BPFO)= # of rollers x shaft speed x 0.4

Ball Pass Frequency Inner Race (BPFI)= # of rollers x shaft speed x 0.6

Fundamental Train Frequency (FTF)= speed x 0.4

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Ref: : www.irdmechanalysis.com

Vibration Severity Chart

Ref: : www.irdmechanalysis.com

Vibration Analysis

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Ref: : www.irdmechanalysis.com

Vibration Analysis - Example

It Can Be Simple

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Blotter

Fresh And Three Aged Samples – Color Change

(Left For 5 Hours At Room Temperature)

R/S Rheometer

‘New’ Tests

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Ruler Test Equipment

‘New’ Tests

Greasing Bearings

Driven EndDriven End

Grease FittingGrease Fitting

Grease PlugGrease Plug

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Greasing Bearings

Slinger RingSlinger Ring

Grease fittingGrease fitting

Greasing Bearings

Volumetric GreaseVolumetric GreaseRelief PortRelief Port

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Grease Quantities

For replenishment from the side of a bearing;

Gp = 0.005 D B

For through the bearing outer or inner ring;

Gp = 0.002 D B

Gp = grease quantity, g

D = bearing outside diameter, mm

B = bearing width (thrust bearings use height H), mm

Ref: SKF 2007

Regreasing Amount Example

6316 ball bearing; ID 80, OD 170 mm Width 39 mm

It should get about 0.005 X 170 mm X 39 mm

= 33 g (1.2oz) of new grease.

With the 70MPa (10,000psi) high pressure greaseguns often used, this can require 43 strokes.

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‘Normal’ Temperature Rise

Ref: Harris, A.F., ‘The Lubrication of Rolling Bearings’, p. 118, ShellInt’l Petroleum Co. Ltd., 1972

Major Causes Of PrematureEngine Bearing Failure

%

Dirt 44.9

Misassembly 13.4

Misalignment 12.7

Insufficient Lubrication 10.8

Overloading 9.5

Corrosion 4.2

Other 4.5

Ref: Clevite AM-208-8

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Better Seals – What is being used?

Reducing MotorBearing Failures

Shell Canada found that at one of theirrefineries, 91% of the problems with motorswere the bearings.

They were able to achieve a 90% reductionin such failures, mainly by better control oflubrication.

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Over Greasing

Preventing Over Pressurization

Provides for pressureProvides for pressure--specific shutspecific shut--off (for example, 20 psi).off (for example, 20 psi).At the given shutAt the given shut--off pressure, the grease flow will stop.off pressure, the grease flow will stop.

$0.35 each$0.35 each

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Thermography

Ref: www.reliableplant.com/Articles/Print/28638

When Is Enough?

Courtesy: EA Grease Caddy

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What to Test and When

This is best based on your specific

equipment, lubes, skill sets and criticality but

there are still good guidelines readily

available.

Example: ASTM D6244 Standard Practice for

In-Service Monitoring of Lubricating Oil for

Auxiliary Power Plant Equipment

For gear/circulating oils, hydraulic oils, diesel

engine oils, turbine type oils, air compressor

oils, EHC (PO4 esters) EHC Mineral Oils.

What Else?

Examine all removed parts including bearings

and filter elements to refine the maintenance

intervals and to learn what is happening.

For filter elements have both low and high

pressure alarms. A differential pressure that

does not increase is reason to check why.

Periodically look inside reservoirs to check

fluid levels, look for foam, look for deposits

and to look for any plunging returns.

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Supply line pressure readings for a filter element. Ifworking correctly there should be a rise in pressuredrops, but not too quick. What changed? Gauges?

Fluid? Dirt? You need to know and take action.

A pluggedservovalvescreen can

bring a halt toproduction.

It is only about1” (35 mm)

long.

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Are we getting better?

Still failures.

Less training and fewer skilled crafts.

More outsourcing.

More ‘penny’ control.

Less innovation.

Less directed training.

Plus, counterfeit part issues.

Wind Turbines – expensive candles

Needs re knowing forces, lube requirements,maintenance and condition monitoring

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Port Hope – water pumps

What happened, why and what warningsigns were missed?

Wheel issue caused 2014 Brockville CN Railtrain derailment, report finds

TSB blamed a combination of factors: the speed of the train,the type of car where the wheel issue manifested itself a 24-

metre-long "centrebeam bulkhead flat car" and the worncondition of the side bearings.

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GM recalling 125,783 cars in Canada; oilleaks can cause engine fires

For the third time in seven years, General Motors is recallingcars that can leak oil and catch fire, in some instances

damaging garages and homes.

The recall, which covers 1.4 million vehicles, including125,783 in Canada, dating to the 1997 model year.

It is needed because repairs from the first two recalls didn’twork. More than 1,300 cars caught fire after they were fixed

by dealers, the company said.

Over time, a valve cover gasket can degrade, allowing oil toseep out. Under hard braking, oil drops can fall onto theexhaust manifold and catch fire. Flames can spread to a

plastic spark plug wire channel and the rest of the engine.

Ref; http://globalnews.ca/news/2301255

Ref: IAEA-TECDOC-1551 Implementation Strategies and Toolsfor Condition Based Maintenance at Nuclear Power Stations

Proactive – How Do You Compare?

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PAS55(Publically Available Specification)

ISO55000

Production

Pumps, motors, fans, compressors, mills, lathes,

or whatever generally have moving and

stationary parts. Between them you need

something to reduce friction and wear. Often

this is a lubricant.

How good it is affects efficiency.

How well it and the bearings are maintainedaffects productivity.

Knowing how these are doing is conditionmonitoring.

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Condition Monitoring - Why

To make the most effective use of materiels by

assessing equipment condition. One goal is get

an early indication of any adverse condition

before it can cause significant consequential

damage, affect production and/or product

quality.

Some techniques can identify problems before

there is damage.

Condition Monitoring - Why

Misalignment, unbalance, loose support bolts,

failing impellors, worn bearings, failing

bearings, lubrication issues, electrical problems,

plugging filters, wrong oil levels, leaks, etc.

Proactive measures can sometimes prevent the

problems in the first place.

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Condition Monitoring - What Else?

Failure mode, effects and criticality analysis

(FMECA) is an extension of failure mode and

effects analysis (FMEA) by including a criticality

analysis. It is used to chart the probability of

failure modes against the severity of their

consequences.

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‘Green’ Lubes

EU Ecolabel

Environmental Choice (Canada)

Green Seal (U. S. A.)

Eco Mark (Japan)

Ecolabel (United Kingdom And Italy)

NF Environment (France)

Blue Angel (Germany)

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What Makes it ‘Green’

Readily biodegradable

Less aquatic toxicity

Does not bioaccumulate

Does not contain mineral oil

Does not contain more than ‘X’ additives

Sustainable

Recyclable

Reusable

Lasts longer

No heavy metals, VOC, or halogens

Recyclable container

Less wear, fuel efficient or better in someregard

Overview

There is not one answer for what to use,

what to monitor or when, where and how.

It depends on the application including the

equipment involved, the process, the cost of

failures, as well as the capabilities of the

personnel plus safety and environmental

considerations.

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Overview cont’d

Fortunately many tools are available for

monitoring.

The key is know what is ‘normal’ and taking the

appropriate actions. Quantifying key

characteristics, trending and bench marking can

be very helpful.

A great deal of good information is readily

available.

Summary

1. Except for gross overloading, mostequipment problems will give someindication of distress ‘long’ before there issignificant consequential damage.

2. An effective condition monitoring programgenerally requires the integration of anumber of techniques and staff.

3. Trend plotting can be extremely helpful toshow degradation and the effectiveness ofproduction and maintenance actions..

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Summary cont’d

4. There has to be realistic measures in place tofoster effective condition based maintenanceand continuous improvement.

5. There has to be enough training to know what isright, what is wrong, who to contact and whatto do.

6. There has to be open lines of communications.

Thank youThank you

www.stle.orgwww.stle.orgwww.stletoronto.comwww.stletoronto.com